Floor panel with a plastic backing

ABSTRACT

Floor panel ( 1 ) comprising a backing ( 2 ) which exhibits a plastics material that is pliable and flexible at the temperature at which a floor is used, comprising a decorative layer ( 3 ) disposed above the backing ( 2 ), comprising complementary mechanical locking means ( 8, 9, 13, 14 ), which are provided at least two edges of the panel ( 1   a   , 1   b   , 1   c   , 1   d   , 11, 12 ), interact in the locked state of two floor panels ( 1 ) and counteract movement apart of the floor panels ( 1 ), wherein at least one of the locking means ( 8, 9, 13, 14 ) is provided at least in certain regions with at least one adhesive (K 1 , K 2 ).

The invention relates to a floor panel comprising a backing whichexhibits a plastics material that is pliable and flexible at thetemperature at which a floor is used, comprising a decorative layerdisposed above the backing, comprising complementary mechanical lockingmeans, which are provided at least two edges of the panel, interact inthe locked state of the two floor panels and counteract movement apartof the floor panels.

A floor panel of this kind is known from DE 199 44 399 A1. It comprisesa backing made of a plastics material that is pliable and yet largelyresistant to dents. Hitherto, hard, rigid wood or wood-like materialshave been used for the backing, but in the known floor panel thismaterial is replaced by a plastics material.

In floor panels which are made of compacted fiberboard and which includemechanical locking means, the quality and strength of the mechanicallocking decrease with a decreasing thickness of the backing. Comparedthereto, a backing made of a plastics material exhibits a higherstrength. It is thus possible to fabricate floor panels that have alower overall thickness than floor panels that comprise a backing madeof a wood fiber material.

A floor covering made up of floor panels of the described kind andessentially consisting of plastics material is suitable for a floatinginstallation, i.e. the floor panels are supported loosely on the ground;an adhesive connection is omitted. Temperature fluctuations make theindividual floor panels expand or shrink. The occurring forces burdenthe mechanical locking and can accordingly cause the floor panels tomove apart thus forming a gap between the adjacent panel edges. Suchgaps are considered to be unaesthetic in a floor covering. Moreover, therobustness of the surface of the floor covering is affected if such gapsare formed.

The invention is based on the object of providing a floor panel that issuitable for counteracting a gap formation.

According to the invention, this object is achieved by at least one ofthe locking means being provided at least in certain regions with atleast one adhesive.

In the assembled state of two floor panels, the form fit of the lockingmeans produces a mechanical locking. Additionally, the mechanicallocking is reinforced by an adhesive connection that is also effectivebetween the assembled mechanical locking means. The strength of theadhesive connection is achieved by the surface cohesion between theadhesive and the respective floor panel on the one side and by theinternal strength of the adhesive itself.

A helpful further development provides an adhesive that is anactivatable adhesive. By this solution, the user is offered the optionto activate the adhesive or to leave the adhesive inactivated andinstead lock the floor panels purely mechanically without an additionaladhesive connection. This is an option, for example, if no excessiveforces on the mechanical locking are to be expected. The user can alsoinstall and lock a flooring cover with the adhesive activated in someregions and non-activated in other regions. If the activation of theadhesive is omitted, it is very easy to unlock and collect the floorpanels for their reuse or reinstallation. For instance, the activationof the adhesive can be effectuated at the second use and repeatedinstallation of a floor covering.

Each of the complementary locking means can be provided with an adhesiveat least in regions.

The adhesive preferably comprises two components which are cured as aresult of a mutual contact.

One embodiment which comprises two components can either be designed insuch a way that it offers the above-described option of activation ofthe adhesive. In this case, the floor panels can be selectively lockedpurely mechanically without an adhesive connection. On the other side,the two components of the adhesive can be applied in such a manner thatthe adhesive is necessarily activated during the process of themechanical form-fit locking. It is possible, for example, to enclose anadhesive in micro capsules which are arranged, e.g. adhered, to thesurface of the locking means. The micro capsules are designed in such amanner that they are destroyed by the process of form-fit locking, sothat the adhesives contained therein leak from the capsules, react witheach another and are cured.

Most simply, the first component of the adhesive is glue and the secondcomponent of the adhesive is a hardener. A contact of the firstcomponentand the second component causes a reaction by which the adhesive iscured.

To simplify the handling, especially during the installation and lockingof the floor panels, the glue component of the adhesive can befactory-provided on a first one of the complementary locking means.

The handling of the floor panels can be additionally simplified byfactory-providing the hardener component of the adhesive on a second oneof the complementary locking means.

As a plastics material of the backing, a material from the group ofthermoplastic elastomers can be provided. These are among othersplastics materials based on polyolefin, polypropylene, polyurethane orpolyamide.

On the other hand, as a plastics material of the backing, a materialfrom the group of amorphous elastomers can be provided. But consideringthat the same exhibit a natural hardness and brittleness, amorphouselastomers of the type containing a plasticizer are provided, forinstance the so-called soft polyvinylchloride (PVC).

The thickness of the floor panel preferably amounts to 1.5 mm to 6 mm.

The floor panel simply has four panel edges.

An expedient embodiment provides that at least one of two mutuallyopposite panel edges has a groove and the opposite panel edge has atongue that is configured complementary to the groove.

An advantageous further development of the groove-and-tongue floor panelprovides that the tongue and the groove each have an undercut, that theundercut of the tongue and the undercut of the groove are designed insuch a way that in a locked state they counteract movement apart of thefloor panels in their plane and vertically to the locked panel edge.

An additional advantageous further development provides that at leasttwo mutually opposite panel edges are provided with complementary hookelements that can be locked with each other in a direction vertical tothe plane of the floor panels.

Of course, it is also possible for a floor panel to be provided with agroove and a tongue on a first pair of mutually opposite panel edges andto include complementary hook elements on a second pair of mutuallyopposite panel edges.

The quality of the mechanical locking by the hook elements can beimproved if each of the hook elements has an undercut which is designedin such a manner that in the locked state a hook connection is producedthat counteracts movement apart of the floor panels vertically to theplane of the floor panels.

Additionally, for improving the dimensional stability, a reinforcementlayer can be provided which includes for instance a fiber-reinforcedmaterial such as fiber glass etc. The reinforcement layer can bearranged as at least one intermediate layer in a split backing.

In the following the invention will be described by way of example andwith reference to the attached drawing figures wherein it isschematically represented by:

FIG. 1 a perspective view of a floor panel including form-fit mechanicallocking means on the panel edges;

FIGS. 2 a, 2 b parts of complementary hook elements as the same can beprovided on mutually opposite panel edges of a floor panel;

FIGS. 3 a, 3 b parts of panel edges including an undercut tongue whichis configured complementary to a panel edge including an undercutgroove, as they can be provided on opposite panel edges of a floorpanel;

FIG. 4 a perspective view of a floor panel including a groove and atongue on a first pair of mutually opposite panel edges andcomplementary hook elements on a second pair of mutually opposite paneledges.

Illustrated in FIG. 1 is a floor panel 1 according to the inventionincluding panel edges 1 a, 1 b and 1 c, 1 d. It comprises a backing 2made of a pliable and flexible plastics material. Above backing 2 adecorative layer 3 is disposed. The decorative layer 3 exhibits areproduction of a wood grain 3 a. On the decorative layer 3 atransparent wear protection layer 5 is provided. Mechanical lockingmeans are provided, namely a first pair of panel edges 1 a and 1 b, thepanel edge 1 a thereof includes a tongue 6 having an undercut 7. Theopposite panel edge 1 b is provided with a groove formed complementaryto the tongue 6. A second pair of mutually opposite panel edges is alsoprovided with a panel edge is that includes a tongue 8 having unundercut while the opposite panel edge 1 d includes a groove 9 with anundercut 10 formed complementary to the tongue 8.

Besides these mechanical locking means also other kinds of mechanicallocking means can be provided on one or both pairs of mutually oppositepanel edges.

In addition to the mechanical locking, the panel 1 d is provided inregions thereof with an adhesive K1 that serves for producing anadhesive connection. In the assembled state of two floor panels theadhesive connection is also effective between the mechanical lockingmeans.

The FIGS. 2 a and 2 b show panel edges 11 and 12 including mechanicallocking means in the form of hook elements 13 and 14. The hook elements13 and 14 each have an undercut surface 13 a respectively 14 a which inthe assembled state of two floor panels prevents movement apart of thefloor panels in their panel plane and also vertically to the lockedpanel edge 11 respectively 12. The undercut surfaces provided for thispurpose are provided on a part 13 b respectively 14 b of the respectivehook element which protrudes vertically to the panel plane. Adjacent tothe vertically protruding part 13 b respectively 14 b a hook recess 13 crespectively 14 c is provided which is configured in such a way that thevertically protruding part 13 b respectively 14 b of the hook element ofthe adjacent floor panel fits in this hook recess 13 c respectively 14c.

The panel edges 11 and 12 are provided in regions thereof with anadhesive. The adhesive comprises a first component K1 that is disposedon the panel edge 12 and a second component K2 that is disposed on thepanel edge 11. The component K1 is glue. In the assembled state of thetwo panel edges 11 and 12, the glue K1 cures as a result of the reactionwith the hardener K2. The form-fit connection of the panel edges 11 and12 is reinforced by a material engagement of the adhesive connection.

The FIGS. 3 a and 3 b show panel edges including a different type ofcomplementary locking means, namely locking means on the basis of agroove and a tongue as already included in the embodiment according toFIG. 1. The panel edge according to FIG. 3 a has a tongue 19 with anundercut 19 a while the panel edge according to FIG. 3 b includes agroove 20 with undercut 20 a formed complementary to the tongue 19. Forlocking the groove and the tongue, the floor panel having the tongue 19is angled in an inclined fashion and the tongue 19 is inserted in thegroove 20. Thereafter, the angled floor panel is pivoted downward to theplane of the other floor panel thus producing a form-fit mechanicallocking.

The panel edges according to the FIGS. 3 a and 3 b are also provided inregions thereof with an adhesive. The adhesive comprises a firstcomponent K1 that is disposed on the panel edge having the tongue 19 anda second component K2 that is disposed on the panel edge having thegroove 20. The component K1 is glue and the component K2 is a hardener.In the assembled state of the groove 19 a and the tongue 20, the glue K1is cured as a result of the reaction with the hardener K2. Also thisform-fit connection of the panel edges is reinforced by materialengagement of the adhesive connection.

According to the FIGS. 3 a and 3 b a decorative layer 3 is provided onan upper face of the floor panel. As indicated by the dashed line, thebacking can be split, with a reinforcement layer V being provided thatimproves the dimensional stability of the floor panel.

FIG. 4 shows in a perspective view an alternative floor panel 1 thatincludes on a first pair of mutually opposite panel edges 1 c and 1 dcomplementary locking means in the form of a tongue 19 having anundercut 19 a. The tongue 19 is provided on a panel edge 1 d. Acomplementary groove 20 having an undercut 20 a is provided on theopposite panel edge 1 c. The second pair of panel edges 1 a and 1 bincludes complementary hook elements 13 respectively 14 as described byway of the FIGS. 2 a and 2 b. The alternative floor panel 1 comprises abacking 2 made of a pliable and flexible plastics material. Above thebacking 2 a decorative layer 3 is disposed. The decorative layer 3carries a reproduction of a wood grain 3 a. On the decorative layer 3 atransparent wear protection layer 5 is provided.

LIST OF REFERENCE NUMBERS

-   1 floor panel-   1 a panel edge-   1 b panel edge-   1 c panel edge-   1 d panel edge-   2 backing-   3 decorative layer-   3 a wood grain-   5 wear protection layer-   6 tongue-   7 undercut-   8 tongue-   9 groove-   10 undercut-   11 panel edge-   12 panel edge-   13 hook element-   13 a undercut surface-   13 b vertically protruding part-   14 hook element-   14 a undercut surface-   14 b vertically protruding part-   19 tongue-   19 a undercut-   20 groove-   20 a undercut-   V reinforcement layer-   K1 first component (glue)-   K2 second component (hardener)

1. Floor panel (1) comprising a backing (2) which exhibits a plasticsmaterial that is pliable and flexible at the temperature at which afloor is used, comprising a decorative layer (3) disposed above thebacking, comprising complementary mechanical locking means (8, 9, 13,14), which are provided at least two edges of the panel (1 a, 1 b, 1 c,1 d, 11, 12), interact in the locked state of two floor panels (1) andcounteract movement apart of the floor panels (1), characterized in thatat least one of the locking means (8, 9, 13, 14) is provided at least incertain regions with at least one adhesive 8 (K1, K2).
 2. Floor panelaccording to claim 1, characterized in that the adhesive is anactivatable adhesive.
 3. Floor panel according to claim 1, characterizedin that each of the complementary locking means (8, 9, 13, 14) isprovided at least in regions thereof with an adhesive (K1, K2).
 4. Floorpanel according to claim 3, characterized in that the adhesive (K1, K2)comprises two components (K1, K2) which are cured by the contact witheach another.
 5. Floor panel according to claim 4, characterized in thatthe first component (K1) of the adhesive is glue and the secondcomponent (K2) of the adhesive is a hardener.
 6. Floor panel accordingto claim 5, characterized in that the adhesive component (K1) of theadhesive is factory-provided on a first one of the complementary lockingmeans (8, 9, 13, 14).
 7. Floor panel according to claim 5, characterizedin that the hardener component (K2) of the adhesive is factory-providedon a second one of the complementary locking means (8, 9, 13, 14). 8.Floor panel according to claim 1, characterized in that as a plasticsmaterial of the backing (2) a material from the group of thermoplasticelastomers is provided.
 9. Floor panel according to claim 1,characterized in that as a plastics material of the backing (2) amaterial from the group of amorphous elastomers is provided, whereinplasticizers are added to the amorphous elastomer.
 10. Floor panelaccording to claim 9, characterized in that the plastics material ispolyvinylchloride (PVC).
 11. Floor panel according to claim 1,characterized in that its thickness amounts to 1.5 mm to 6 mm.
 12. Floorpanel according to claim 1, characterized in that it includes four paneledges (1 a, 1 b, 1 c, 1 d, 11, 12).
 13. Floor panel according to claim12, characterized in that at least one of two mutually opposite paneledges (1 a, 1 b, 1 c, 1 d, 11, 12) is provided with a groove (20) andthe opposite panel edge is provided with a tongue (19) formedcomplementary to the groove.
 14. Floor panel according to claim 13,characterized in that the tongue (19) and the groove (20) each includean undercut, that the undercut (19 a) of the tongue (19) and theundercut (20 a) of the groove (20) are designed in such a manner that inthe locked state they counteract movement apart of the floor panels (1)in their plane and vertically to the locked panel edge (1 a, 1 b, 1 c, 1d, 11, 12).
 15. Floor panel according to claim 12, characterized in thatat least two mutually opposite panel edges (1 a, 1 b, 1 c, 1 d, 11, 12)are provided with complementary hook elements (13, 14) that are lockableto one another in a direction vertical to the plane of the floor panels(1).
 16. Floor panel according to claim 15, characterized in that eachof the hook elements (13, 14) includes an undercut surface (13 a, 14 a)that is designed in such a manner that in the locked state a hookconnection is produced that counteracts movement apart of the floorpanels (1) vertically to the plane of the floor panels (1).
 17. Floorpanel according to claim 1, characterized in that a reinforcement layer(V) is provided.
 18. Floor panel according to claim 17, characterized inthat the reinforcement layer (V) includes fiber-reinforced material. 19.Floor panel according to claim 17, characterized in that thereinforcement layer (V) is arranged as at least one intermediate layerin a split backing (2).